Dynamic Cable Assembly with Removable Armor Retainer
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Solution Overview
Problem
Existing dynamic cable assemblies for drilling and mining operations are heavy, inflexible, and have a large outer diameter, leading to reduced run life and limited bending radius, which results in costly downtime and are not field-repairable.
Innovation Solution
A cable assembly design featuring thick inner cable jackets with aramid fiber reinforcement, high-strength dielectric resin, metallic armor for support and grounding, and a flange assembly with a separate armor retainer for secure attachment, eliminating the need for a potted hose, allowing for temporary field repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a potted hose design is used to protect cable components, then the cable assembly is protected against damage, but the assembly becomes very heavy and relatively inflexible with a large outer diameter
Solution Approach 1:
The patent removes the heavy potted hose design from the cable assembly, extracting only the essential protective functions. The cable components are protected through alternative means such as individual cable armors, jackets, and strategic placement of potting material only at critical connection points rather than encasing the entire assembly in a heavy hose.
Solution Approach 2:
The cable assembly is divided into separate protected components rather than a single monolithic potted structure. Each cable (electrical wires, hydraulic lines, fiber optic cables) maintains its own protective layers, and the assembly uses modular connection points with potting material applied selectively at flange interfaces rather than throughout the entire length.
2Reliability
If a potted hose design is used to protect cable components, then the cable assembly is protected against damage, but the assembly becomes relatively inflexible with limited bending radius
Solution Approach 1:
The restrictive potted hose is removed entirely from the cable assembly design. Protection is achieved through individual cable armors and selective potting at connection points, allowing the cables to bend and flex naturally without being constrained by a rigid outer hose structure.
Solution Approach 2:
The cable assembly is designed to be dynamically flexible rather than statically rigid. The individual cable construction with separate armors and the selective application of potting material allow the assembly to adapt its shape and bending radius according to operational requirements, maintaining flexibility while providing protection.
3Strength
If a potted hose design is used, then the cable components are supported, but the assembly size increases limiting effective bending radius
Solution Approach 1:
The bulky potted hose structure is extracted and replaced with compact protective elements. Cable components are supported through their own inherent strength (individual armors and jackets) and strategic potting material application at connection points, eliminating the need for a large-diameter enclosing hose.
Solution Approach 2:
Protection and support are applied locally rather than uniformly throughout the entire assembly. Potting material is used selectively at critical connection points and flange interfaces where structural support is most needed, while the main cable length maintains its own protective layers without additional bulk, minimizing overall assembly diameter.
4Reliability
If the cable assembly is designed with heavy protection, then durability is improved, but the assembly becomes non-field-repairable requiring complete replacement when damaged
Solution Approach 1:
The cable assembly is segmented into independent, replaceable components rather than a monolithic unit. Individual cables maintain their own protective layers and can be accessed separately at connection points, allowing damaged sections to be repaired or replaced without compromising the entire assembly or requiring removal of heavy protective housing.
Solution Approach 2:
The cable assembly is designed with pre-configured access points and modular connection structures that facilitate future repair actions. Flange connections and selective potting arrangements are established during manufacturing to enable easy disassembly and reassembly in the field, allowing technicians to access and repair individual cables without requiring specialized equipment or complete assembly replacement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design results in a lighter, more flexible cable assembly with increased run life, improved durability under dynamic loads, and reduced downtime due to the ability for temporary repairs, while also providing electromagnetic interference protection and reduced weight and size.
Implementation Method 1
a thick inner cable jacket with reinforced aramid fibers designed to carry the load of the assembly
Implementation Method 2
a high-strength, high-dielectric resin chemically bonded to the inner jacket of the cable as well as to the assembly support flange
Implementation Method 3
a high-strength, high-dielectric resin
Implementation Method 4
An overall metallic armor provides both additional cable support and electrical grounding
Implementation Method 5
A braid shielding for power cables provides a unique grounding arrangement within the flange body itself
Data Source
AI summary
A flange assembly for supporting a cable has a flange body and an armor retainer. The flange body and the armor retainer are configured to support a cable by compressing an armor layer of the cable against the armor retainer. The armor retainer and the flange body are separate pieces, that are removably attachable to one another.